QUALITY CONTROL TECHNIQUES

Project Made By –

Rahil Parkar- Roll No. 30

Mihir Thakkar- Roll No. 45

Sub: - Productivity and quality management

Std- S.y.b.m.s IVth Semester

Submitted to: -
Prof. Mili Sharma
 Acknowledgement
We are happy and very satisfied at this moment to
represent this project. This was not just due to the
efforts made by us but also due to the proper guidance
and advice by our professor Ms.Mili Sharma. The
completion of this project would not be possible
without the help and guidance given to us by Ms.Mili
Sharma. We also express our hearted thanks to our
college librarian for her support and co-operation.
Thanks and Regards,
Rahil M. Parkar
Mihir P. Thakkar

Contents
 1. Introduction
2. Types Of quality control techniques
2.1 Kanban
2.2 Poka Yoke
2.3 Jidoka
2.4 Kaizen
3. Conclusion
4. Bibliography

INTRODUCTION
Everyone is being exposed to the "zero defects" philosophy that establishes zero
as a goal. This will not be achieved overnight but approached over time by
continually striving to reduce targets. What kinds of techniques are needed to
assure zero defects? What constitutes an out-of-control situation? An attributes
control chart conveys little information at or near zero defects. Assuring zero
defects through sampling inspection leads to infinite samples or 100 percent
inspection, assuming 100 percent inspection efficiency (the latter rarely exists,
and efficiency probably gets worse at lower defect levels). Obviously, some
new approaches to quality control (QC) techniques will be necessary at zero
defects. Total Quality Control is the most important inspection control of all in
cases where, despite statistical quality control techniques or quality
improvements implemented, sales decrease. If the original specification does
not reflect the correct quality requirements, quality cannot be inspected or
manufactured into the product. For instance, the parameters for a pressure
vessel should include not only the material and dimensions, but also operating,
environmental, safety, reliability, and maintainability requirements. The
company-wide quality approach places an emphasis on three aspects: -
1. Elements such as controls, job management, defined and well managed
processes, performance and integrity criteria, and identification of records
2. Competence, such as knowledge, skills, experience, and qualifications
3. Soft elements, such as personnel integrity, confidence, organizational
culture, motivation, team spirit, and quality relationships.
The quality of the outputs is at risk if any of these three aspects is deficient in
any way.
There are four types of quality control techniques, they are as follows:-
1. Kanban
2. Poka Yoke
3. Jidoka
4. Kaizen

Types of Quality Control Techniques: - The types of

quality control techniques are as follows.

➢ Kanban

Kanban is a concept related to

lean and just in time (JIT)
production. According to Taiichi
Ohno, the man credited with developing JIT, Kanban is a means
through which JIT is achieved. The Japanese word Kanban is a
common term meaning "signboard" or "billboard.”

➢ E-Kanban systems
Many manufacturers have implemented electronic kanban
systems. Electronic kanban systems, or E-Kanban systems, help
to eliminate common problems such as manual entry errors
and lost cards. E-Kanban systems can be integrated into
enterprise resource planning (ERP) systems. Integrating E-
Kanban systems into ERP systems allows for real-time demand
signaling across the supply chain and improved visibility. Data
pulled from E-Kanban systems can be used to optimize
inventory levels by better tracking supplier lead and
replenishment times.

➢ Poka Yoke
Poka yoke is a Japanese term that
means mistake proofing. A Poka yoke
device is one that prevents incorrect
parts from being made or assembled,
or easily identifies a flaw or error.

Poka-yoke - 'mistake-proofing', a means of providing a visual

or other signal to indicate a characteristic state. Often referred
to as 'error-proofing', poke-yoke is actually the first step in truly
error proofing a system. Error proofing is a manufacturing
technique of preventing errors by designing the manufacturing
process, equipment, and tools so that an operation literally
cannot be performed incorrectly.

➢ Jidoka
 Autonomation describes a feature of machine design to
affect the principle of
jidoka used in the Toyota
Production System (TPS)
and Lean manufacturing. It
may be described as
"intelligent automation" or
"automation with a human
touch.” This type of
automation implements
some supervisory functions rather than production functions. At
Toyota, this usually means that if an abnormal situation arises
the machine stops and the worker will stop the production line.
Autonomation prevents the production of defective products,
eliminates overproduction, and focuses attention on
understanding the problem and ensuring that it never recurs. A
quality control process applies the following four principles:

1. Detect the abnormality.

2. Stop.
3. Fix or correct the immediate condition.
4. Investigate the root cause and install a countermeasure.

➢ Relationship with "just-in-time"

Taiichi Ohno and Sakichi Toyoda, originators of the TPS and
practices in the manufacturing of textiles, machinery, and
automobiles considered JIT & Autonomation the pillars upon
which TPS is built. Jeffrey Liker and David Meier indicate that
Jidoka or "the decision to stop and fix problems as they occur
rather than pushing them down the line to be resolved later" is
a large part of the difference between the effectiveness of
Toyota and other companies who have tried to adopt Lean
Manufacturing. Autonomation therefore can be said to be a key
element in successful Lean Manufacturing implementations. For
"just-in-time" (JIT) systems, it is vital to produce with zero
defects, or else these defects can disrupt the production
process - or the orderly flow of work.
➢ Kaizen
Kaizen is a Japanese term that
has been adopted into English.
Kaizen refers to a philosophy or
practices that focus upon
continuous improvement in
manufacturing activities,
business activities in general,
and even life in general,
depending on interpretation and
usage. By improving
standardized activities and
processes, kaizen aims to
eliminate waste. Kaizen was first implemented in several
Japanese businesses during the Japanese post-war economic
miracle and has since spread to businesses throughout the
world.
Implementation
The Toyota Production System is known for kaizen, where all
line personnel are expected to stop their moving production
line in case of any abnormality and, along with their supervisor,
suggest an improvement to resolve the abnormality, which may
initiate a kaizen.

The cycle of kaizen activity can be defined as:

• Standardize an operation
• Measure the standardized operation (Gauge
measurements against requirements).
• Innovate to meet requirements and increase productivity
• Standardize the new, improved operations
 • Continue cycle ad infinitum
This is also known as the Shewhart cycle, Deming cycle, or
PDCA.
Key elements of kaizen are quality, effort, and involvement of
all employees, willingness to change, and communication.
The five main elements of kaizen:-
• Teamwork
• Personal discipline
• Improved morale
• Quality circles
• Suggestions for improvement
Major results:-
• Elimination of waste (muda) and incorporation of
efficiency
• The kaizen 5S framework for a well organized shop floor
○ Seiri - tidiness
○ Seiton - orderliness
○ Seiso - cleanliness
○ Seiketsu - standardization
○ Shitsuke - sustaining the discipline.

Conclusion
Quality Control techniques are in much more detail than the
above document has illustrated. If used effectively and
efficiently these techniques can help an organization or
business to achieve a six-sigma performance with zero defects,
elimination of waste or waste management, building up of team
work and new innovation techniques. With the help of these
quality control techniques such as kanban, poka yoke, jidoka,
and kaizen a total quality management (TQM) can be achieved.
 Bibliography

Websites
✔ Wikipedia.org
✔ Scribd.com
✔ Deming.org
✔ Managementwisdom.com

Books
✔ Shewhart, Walter A (1930). Economic Control of
Quality of Manufactured Product/50th Anniversary
Commemorative Issue December 1980.
✔ Deming, W. Edwards (1966). Some Theory of
Sampling. Dover Publications.
✔ Productivity and Quality Management (2009).Vipul
Prakashan.
✔ Productivity and Quality Management (2009).
Himalaya Publishing House.